R4TECH PRODUCT SAFETY NOTICE

Transcription

1 R4TECH PRODUCT SAFETY NOTICE Congratulations. This vehicle has been equipped with an R4Tech suspension system that provides the ride quality of a full-air suspension with the ease of installation of a standard leaf spring and Ride-Rite kit. This suspension will enhance the vehicle s handling when loaded, however, the vehicle s performance may be altered so that the steering, braking and handling characteristics of this vehicle may differ from passenger cars and trucks not equipped with this type of suspension. A vehicle that is loaded will require more distance to stop. A load may alter the vehicle s center of gravity; therefore, extreme caution must be used to avoid abrupt maneuvers, sudden sharp turns, and other driving conditions that could result in loss of control or rollover of the vehicle. Such a loss of control or rollover could result in serious injury or death. Since the R4 Tech suspension system is a modification to your vehicle s suspension, it is recommended that a professional mechanic perform the installation. Keep in mind that your vehicle, while loaded, will exhibit different handling characteristics than when unloaded. Always exercise caution when driving, reduce your speed when noted and fasten your seatbelts. Please keep your installation instructions and warnings with your vehicle s owner s manual for the service life of the vehicle and provide that information to any subsequent purchasers or others who may use the vehicle with the R4Tech system installed. If you need any additional decals, installation or warning materials, call for replacement materials. DEALER/INSTALLER NOTICE Enclosed with the R4Tech suspension system are two safety warning decals which must be attached to the passenger s and driver sun visor as a supplement to the FMVSS warnings if they are in place. The decal is a safety reminder to the operator and passengers that the vehicle has been modified with an R4Tech suspension system. It is the responsibility of the installer: (1) to affix the warning decals on the sun visors; and, (2) to provide to the end user the installation instructions and warnings that are included with the R4Tech suspension system. The installation instructions and warnings should be kept with the vehicle owner s manual in the vehicle s glove box at all times. It is a condition of the product warranty that the decals be affixed while the system is installed. If you need additional decals for the vehicle, please contact Customer Service at for replacement materials.

2 WC Before beginning the installation, please read the following instructions and the drivers warning notice thoroughly. The included warning decal must be placed in the passenger compartment in clear view of all occupants. NOTE: If any items are missing from this kit or you need assistance with installation, call for technical assistance. DO NOT return to your dealer. Start with the vehicle parked on a hard (concrete or asphalt) level surface. Using a measuring tape, measure the distance from the ground to the center of the fender opening, directly above the axle. Record the measurements below for a reference later in the installation. Driver s (Left) rear: Passenger s (Right) rear: NOTE: Before disassembling your vehicle, compare the parts in the box(s) with those listed in the parts list(s). Required tools: Floor Jack Jack Stands Vice Grips Measuring Tape Air Line Tubing Cutter Electric Drill 1/2 Drill Bit #2 Phillips Screw Driver 7/32 Allen Wrench Torque Wrench Ratchet 3/8 Wrench & Socket 7/16 Wrench & Socket 9/16 Wrench & Socket 3/4 Wrench & Socket 1-1/8 Wrench & Socket 15MM Wrench & Socket 18MM Wrench & Socket 21MM Wrench & Socket 24MM Wrench & Socket NAD-37538

3 Parts List Item # Description Part # Quantity (ea.) 1. Air Spring W R4 Tech Spring 2 3. J-Link 2 4. Outer Front Spring Hanger 2 5. Inner Front Spring Hanger 2 6. Lower Spring Mount 2 7. Lower Frame Clamp 2 8. U-Bolt bracket 2 9. Height Control Valve Bracket (L), 5668(R) Linkage Bracket Lower Air Spring Bracket Upper Air Spring Bracket Compressor Mount Heat shield Air Proportioning Shock Air Tank Compressor WR Air Line Frame Mount Bracket Height Control Valve Linkage Axle U-Bolt U-Clamp 2 Tee Fitting WR Straight Fitting WR Elbow Fitting WR Compressor Tee WR

4 Parts List (cont.) Item # Description Part # Quantity (ea.) Pressure Switch WR /8-16 x 8-3/4 Bail Clamp 4 10/32 Machine Screws 4 10/32 Hex Bolts 4 10/32 Hex Nuts 4 10/32 Nylock Nuts 4 #10 Washers 8 1/4-20 x 1 Hex Bolts 4 1/4-20 x 1-1/2 Hex Bolts 4 1/4-20 Nylock Nuts 8 3/8-16 x 2-1/2 Flat head Bolts 4 3/8-16 Centering Bolt 2 3/8-16 Flange Nuts 14 1/2-13 x 1 Hex Bolts 2 9/16"-20 x 1-1/4" Hex Bolt 8 9/16"-20 Hex Nuts 4 9/16" Washers 12 3/4-16 Hex Nuts 2 3/4 Star Washers 2 M21 Hex Bolts 6 M21 Hex Nuts 6 M24 Hex Bolts 2 M24 Hex Nuts 2 Large Flat Washers 14

5 Prior to any removal or installation of any product, measure the distance from the lip of the wheel well opening to the ground and record this measurement on the front page of these instructions. All images are of the passenger side, or right side, of the truck. See page # for the component layout and familiarize yourself with the parts which will be referenced in the installation procedures. Removal of Stock Components 1) Tools needed: 24MM socket and ratchet. Using a floor jack and jack stands rated for your vehicle, lift the vehicle by the frame until the tires are off the ground. Place the jack stands under the frame and remove the tires. Place the floor jack under the differential and apply enough pressure to remove some tension on the leaf springs. Remove the nuts on the axle u-bolts and discard. *Keep the u-bolt retainers shown in Figure A * 2) Tools needed: 18MM wrench, socket and ratchet. Remove the shock for the vehicle and retain the hardware. Lower the floor jack and allow the axle disengage from the leaf springs. DO NOT put tension or strain on the flexible brake line. Figure A 3) Tools needed: 24MM wrench & socket, 21MM wrench & socket and ratchet. *On trucks with a factoryinstalled receiver hitch, the hitch must be removed and reinstalled at the end of the product installation. Use a 21MM socket and wrench to remove the hitch hardware.* Remove the leaf springs and hardware from the spring hangers and the swing shackle and its hardware. Retain the swing shackle and its hardware. See Figures B & C. Figure C Figure B

6 The front spring bolts will use a 24MM socket and wrench, and the rear will use a 21MM. *On some models, the driver s front hanger bolt will have to be cut to be removed.* Remove the cross member bolt and retain. 4) Tools needed: 15MM socket and ratchet. Remove the jounce bumper from the bottom of the frame. This will not be reused. Installation of R4Tech Components NOTE: All bolts should be paired with a washer, and all hex nuts should be paired with a washer. Flange nuts, flange bolts, and welded nuts do not require washers. Figure D 1) Remove the cross member bolt from the inside of the frame. See Figure D. Place the inner front hanger bracket bracket on the frame, forward of the front spring hanger, so the hook goes over the top of the frame and captures the inside lip of the frame. Install the outer front hanger bracket and use the front hanger bolt to keep them in place. *Note: on passenger s side, install the J-spring and bolt, with the bolt head to the inside, prior to installing the outer hanger bracket.* Swing the hanger brackets into place and attach them to the frame clamp using the 9/16"x1-1/4" hex bolts and washers tightened hand tight, as shown in Figure E. Reinstall the cross member bolt into the slotted hole in the bracket. 2) Place the lower frame clamp bracket over the frame and attach it to the hanger brackets with the 9/16"x1-1/4" hex bolts, washers, and nuts tightened hand tight, as shown in Figure F. 3) Tools needed: 3/8" socket, ratchet, and 7/32 allen wrench. Select a height control valve mounting bracket (5667 left, 5668 right) and a height control valve. Attach the valve to the bracket using the 1/ 4"-20 x 1" hex bolts and nylock nuts. See Figure G. Insert the wooden pin into the hole on the rearward side of the arm to prevent the arm from moving and inflating the bags prior to the end of the installation. DO NOT install the linkage at this time. Next, install the upper air spring bracket and height control valve bracket onto the frame with two 3/8"-16 flat head bolts and flange nuts. *NOTE: the height control valve bracket will be installed between the frame and the upper air spring bracket.* See Figure H. Figure F Figure E

7 4) Tools needed: Vice Grips, 9/16 wrench, 3/4" socket and ratchet. Using the 3/8-16 x 1 allen head centering bolt and nut to attach the link bracket to the lower air spring bracket. See Figure I. *HINT: tape the nut to the wrench to hold it in place while the centering bolt is tightened. Next, attach the air spring to the lower air spring bracket with a 1/2"-13 x 1" hex bolt and washer finger tight. Place the assembly on the axle, making sure the head of the centering bolt inserts into the alignment hole on the axle. Secure the tab on the inboard side of the lower bracket to the axle using the u-bolt and clamp. See Figure J. Figure G 5) Tools needed: 24MM socket & wrench, 21MM socket & wrench, and ratchet. Select one R4 Tech leaf spring from the kit. Install the swing shackle with the bolt removed earlier onto the single leaf end of the spring. Install the leaf spring on the vehicle using the supplied hardware so that the swing shackle goes to the rear, and the forward end installs into the upper hole of the spring hanger brackets. See Figures K & L. Tighten hand tight. *NOTE - use 24MM nuts & bolts on the front, and 21MM nuts & bolts on the rear.* Figure H Figure I Figure J Figure K

8 6) Tools needed: 21MM socket & ratchet and wrench. Install J- link onto the truck with the opening towards the rear. See Figure M. Place the u-bolt bracket over the u-bolts and align the holes with the holes in the link bracket. See Figure O.Use the 21MM nuts and bolts provided. 7) Tools needed: 1-1/8" wrench and 9/16" wrench, 3/4" wrench. Lift the axle back into place guiding the alignment pin on the leaf spring assembly into the alignment hole on the spring mount, and the combo stud of the air spring into the mounting hole on the upper bracket. The alignment pin on the air spring will be inserted into the forward hole in the upper bracket. Attach the air spring to the upper bracket using a 3/ 4"-16 hex nut and star washer. Next, install the male fitting into the air inlet in the combo stud of the air spring. Tighten the air fitting securely to engage the orange thread sealant. Tighten the mounting bolt in the bottom of the air spring. See Figure N. Figure L 8) Tools needed: 24MM socket, ratchet, & torque wrench. Install the axle u-bolts, height control linkage bracket, and the u-bolt retainer. The linkage bracket installs between the u-bolts and the leaf spring. After both sides are installed, Tighten the u-bolts to 118 ft/lbs. See Figure O. 9) Tools needed: 18MM wrench, socket and ratchet. Install the air proportioning shocks using the original hardware. The air line will be installed later. Torque the shockbolts to 85 ft/lbs. 10) Reinstall the factory hitch if present. Figure M Figure N Figure O

9 Installation of the Air Control System. 1) Tools needed: 9/16" wrench, socket, and ratchet. Install the male fittings into the ends of the tank and the drain valve into the offset port. Tighten the fittings securely to engage the orange thread sealant. Next, install the tank mounting brackets onto the mounting flanges of the tank using 3/8"-16 flange lock nuts. See Figure P. Attach the tank to the frame using the bail clamps and 3/8"-16 flange lock nuts. The drain valve needs to be below the male fitting as shown in Figure Q. 2) Tools needed: Phillips head screw driver, 3/8" wrench, 9/ 16" socket, and ratchet. Using the 10-32" machine screws, washers, and nylock nuts, attach the compressor to the compressor mounting bracket. Place the black compressor wire onto one of the mounting screws. Do Not over-tighten or crush the brass insert and the rubber isolator. Attach the compressor mounting bracket to the frame mounting brackets using 3/8"-16 flange lock nuts. See Figure R. Figure P Figure Q 3) Tools needed: 9/16" wrench. Install the compressor tee fitting into the head of the compressor and the pressure switch into the tee fitting. Tighten the fittings securely to engage the orange thread sealant. Connect the red compressor wire to one of the terminals on the pressure switch. Attach the compressor assembly to the frame near the tank and secure with the bail clamps and 3/8"-16 flange lock nuts, as shown in Figure S. Route a section of air line from the compressor tee fitting to one of the male fittings on the tank. 4) Install the relay harness on the vehicle. Attach the green ring terminal to a suitable ground source. Connect the red ring terminal to the (+) battery terminal, and the red female spade terminal to the pressure switch. The white wire will connect to an ignition controlled power source. Figure R 5) Tools needed: Drill and 1/2" drill bit. This R4 Tech kit includes a dump switch that allows the vehicle to be put into a kneeling or lowered mode for loading and unloading of cargo. Do not drive in the kneeled position. Driving the vehicle while kneeled adversely affects the handling of the vehicle and will cause damage to the suspension components. Select a convenient mounting location for the dump switch and drill a 1/2" hole. When looking at the switch, notice the arrow position on the sides. Figure T Figure S

10 The arrow on the inlet side will point towards the switch lever, and the arrow on the outlet side will point away from the switch lever. While looking at the inlet side, the switch lever in the up position will maintain the ride height, and the switch lever in the down position will kneel the vehicle. Remove the plastic hex nut, push the treaded portion through the 1/2" hole, and reinstall the plastic hex nut and tighten finger tight. See Figure T. Figure V 6) Tools needed: Air Line tubing cutter. Route a section of air line from the tank towards the height control valve and install a tee fitting. From the tee fitting, route an air line to the SUP (bottom) ports on the height control valves. Splice this line and add another tee fitting. From this tee, route an air line to the inlet on the dump switch. See Figure U. 7) Tools needed: Air Line tubing cutter. Route a section of air line from each of the pilot ports on the dump valve (middle port) to a tee fitting. Next, route another section of air line from the tee fitting to the outlet side of the dump switch. See Figure U. 8) Tools needed: Air Line tubing cutter. Route a section of air line from the air spring to the open fitting on the side of the dump valve, next to the pilot port. See Figure U. 9) Tools needed: Air Line tubing cutter. Cut the air line from the air spring and install a 1/4" x 1/4" x 5/32" tee fitting. Route a section of 5/32" air line from the tee fitting to fitting on the shock. See Figure U. Pressurizing the System and Setting the Ride Height 1) Lower the vehicle back to the ground and remove all jacks and jack stands. Turn on the vehicles ignition to power the compressor and fill the air tank. 2) Using a floor jack under the frame, lift the rear of the vehicle to the pre-recorded heights that were measured prior to the installation. 3) Tools needed: 7/16" & 3/8" wrench, socket, and ratchet, hack saw. Once the truck has been raised to its original height, and the height valve is locked in its level position with the wooden pin (Figure V ), measure the distance from the center of the mounting hole on the arm of the height control valve to the center of the mounting hole on the height control linkage bracket, which was installed between the leaf spring retainer and the leaf spring. Measure and cut the two pieces of linkage to equal this measurement. Attach the two pieces of linkage together using 10/32" bolts, washers, and nuts. Mount the linkage to the height control valve and linkage bracket using the 1/4"-20 bolts and nuts. See Figure V. 4) Remove the wooden pin from the height control valve, lower the frame, and remove the jack. The height control valve will inflate the air springs and return the truck the original height. Completing the Installation and Test the System 1) With the vehicle at ride height, torque the hardware on the frame clamp brackets to 37 ft/lbs, then the spring hanger bolts to 148 ft/lbs. Next, torque the J-link bolts to 169 ft/lbs. Torque the swing shackle bolts to 70 ft/lbs. 2) Flip the dump switch down to kneel the vehicle. The air springs should deflate and the rear of the vehicle will lower. 3) Flip the dump switch up to return the vehicle to ride height. The air springs should inflate and the rear of the vehicle will rise.

11 1/4 AIR LINE (OUT TO PILOT PORT) Figure U RELAY 1/4 AIR LINE (TANK TO INLET) DUMP SWITCH RED TO PRESSURE SWITCH RED TO PRESSURE SWITCH PRESSURE SWITCH GREEN TO GROUND RED BATTERY (+) WHITE IGNITION (+) DRAIN VALVE AIR TANK FROM DUMP SWITCH TO PILOT PORT FROM TANK TO SUP. PORT BLACK TO GROUND COMPRESSOR FROM DUMP SWITCH TO PILOT PORT TEE FITTING FROM TANK TO SUP. PORT 5/32 AIR LINE AIR PROPORTIONING SHOCKS 5/32 AIR LINE EXHST PILOT SUP HEIGHT CONTROL VALVE HEIGHT CONTROL VALVE LINKAGE LINKAGE AIR SPRING AIR SPRING

12 Trouble Shooting the R4 Tech System The compressor will not turn on to pressurize the system. Check the wiring from the wire harness. Make sure the battery (+) connection, ignition activated power source, and all ground connections are suitable. Make sure the connections wires going to the pressure switch are connected. The compressor runs constantly / excessively. If the suspension is not being loaded and unloaded and the compressor runs constantly or excessively, there is a leak between the compressor and the tank or the tank and the height control valve. Make sure the drain valve is closed tightly. Make sure the air lines are pushed into the fittings completely. Tighten the fittings on the tank, compressor, and height control valve an additional 1/4 to 1/2 turn. If the system still leaks, the leak point can be detected with a soapy water solution. Spray the mixture on the fitting connections and air line, moving slowly from one end to the other, looking for bubbles. If leak is found where a fitting threads into a component, tighten the fitting an additional 1/4 to 1/2 turn. If the leak is detected where the line pushes into the fitting, make sure the line is pushed into the fitting completely. If the leak persists, remove the line by pushing the collar on the fitting toward the body of the fitting. While holding the collar in, pull out the tubing. Cut the tubing squarely and push the tubing into the fitting as far as possible. The dump switch will not kneel my vehicle. Follow the air line from the switch from the dump switch to the dump valve making sure there are no kinks in the line. Make sure the air line on the inlet side of the dump switch is routed to the SUP (bottom) port on the height control valve. Make sure the air line from outlet side of the dump switch is routed to the pilot port (middle port) on the dump valve. The pilot port is on the end of the dump valve not the side of the dump valve. The port on the side of the dump valve should be routed to the air spring. My vehicle will not level when a load is applied. Make sure the linkage is connected between the height control valve and the linkage bracket. Check that the tank is pressurized by slowly opening the drain valve. If there is no pressure in the tank, refer to the procedure above for checking system power.

13 Kits and quantity required for complete system installation Master Kit Pkg. Qty. 2 Pkg. Qty. 1 Pkg. Qty. 1 Pkg. Qty. 1 Pkg. Qty. 1 Pkg. Qty. 1 Pkg. Qty. 1 Leaf springs Links Differential bracket Frame bracket Air spring kit Air control kit Load adaptive shocks Vehicle Year Chevrolet/GMC Pickup Trucks W W4T-000-G01S W4T-000-GL01 W4T-000-GD01 W4T-000-GB01 W4T W4T WR C2500 (4x2, 4x4) short bed, 10.5" axle W W4T-000-G01S W4T-000-GL01 W4T-000-GD01 W4T-000-GB02 W4T W4T WR C2500 (4x2, 4x4) long bed, 10.5" axle W W4T-000-G02S W4T-000-GL01 W4T-000-GD02 W4T-000-GB01 W4T W4T WR C3500 (4x2, 4x4) short bed SRW/DRW, 11.5" axle W W4T-000-G02S W4T-000-GL01 W4T-000-GD02 W4T-000-GB02 W4T W4T WR C3500 (4x2, 4x4) long bed, SRW/DRW, 11.5" axle The master kit (complete suspension system) is made up of the different sub-kits. Each master kit should include (2) leaf spring kits, (1) link kit, (1) differential bracket kit, (1) frame bracket kit, (1) air spring kit, (1) air control kit, and (1) load adaptive shock kit, which contains (2) shocks. The sub-kits will have to be ordered in their respective quantities.